System of collapsible panels and structures

ABSTRACT

A collapsible structure is provided with a plurality of panels, the plurality of panels including at least a first panel and a second panel, each panel having a foldable metallic frame member that has a folded and an unfolded orientation, with a fabric material covering portions of each respective frame member to form the panel for each frame member when the frame member is in the unfolded orientation, each panel having a left side and a right side, with the left side of one panel hingedly coupled to the right side of an adjacent panel. A magnetic connector connects a separate item to a portion of the frame member of one of the panels.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to collapsible panels and structures, and in particular, to collapsible panels and structures which can be connected by a system of magnetic connectors.

2. Description of the Prior Art

There are presently many collapsible structures that are being provided for use by children and adults in a number of different applications. Examples of these collapsible structures are illustrated in the following patents: U.S. Pat. No. 5,816,954 (Zheng), U.S. Pat. No. 6,006,772 (Zheng), U.S. Pat. No. 5,778,915 (Zheng), U.S. Pat. No. 5,467,794 (Zheng), U.S. Pat. No. 5,975,101 (Zheng), U.S. Pat. No. 5,722,446 (Zheng), U.S. Pat. No. 4,858,634 (McLeese), U.S. Pat. No. 4,825,592 (Norman), U.S. Pat. No. 5,964,533 (Ziglar), U.S. Pat. No. 5,071,188 (Kellogg et al.), U.S. Pat. No. 6,485,344 (Arias), U.S. Pat. No. 6,343,391 (LeGette), U.S. Pub. No. 2004/0139997 (Zheng) and U.S. Pat. No. 5,038,812 (Norman), among others. These collapsible structures are supported by one or more frame members that can be twisted and folded to reduce the overall size of the structure. These collapsible structures can be used in a wide variety of applications, such as containers, tents, play structures, executive toys, shelters, sports structures, and others. As a result, collapsible structures have become very popular.

Most of these previous collapsible structures are preformed into specific configurations of panels that are stitched together. As such, they can only be used in their preformed configurations and the play variety often wanes over time. Attempts were made to provide separate panels that can be removably or adjustably attached to other panels or structures. For example, U.S. Pat. No. 6,220,265 to Zheng discloses the use of opposite VELCRO™ pads and other fabric connectors to connect panels. However, while the fabric connectors allow for the panels to be adjusted or replaced, the variations available to the user are still rather limited. In addition, VELCRO™ pads are also rather limiting in use because two opposing (male and female) pads are needed, and these pads need to be secured to specific locations on different panels. As a result, the user is still limited in that he or she can only effectuate a connection at specific pre-set locations along different panels.

SUMMARY OF THE DISCLOSURE

It is an object of the present invention to provide a system of collapsible panels and structures that can be conveniently assembled and disassembled at a variety of locations at the discretion of the user.

In order to accomplish the objects of the present invention, a collapsible structure is provided with a plurality of panels, the plurality of panels including at least a first panel and a second panel, each panel having a foldable metallic frame member that has a folded and an unfolded orientation, with a fabric material covering portions of each respective frame member to form the panel for each frame member when the frame member is in the unfolded orientation, each panel having a left side and a right side, with the left side of one panel hingedly coupled to the right side of an adjacent panel. A magnetic connector connects a separate item to a portion of the frame member of one of the panels.

In another embodiment, a magnetic connector is permanently secured to a portion of the fabric material at a location offset from the frame member, with a separate item having a portion thereof that is made of metal, and being removably attached to the magnetic connector at the location of metal portion.

In yet another embodiment, two or more magnetic connectors can connect two or more panels together at the fabric portion of these panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a system of collapsible panels and structures according to one embodiment of the present invention.

FIG. 2 is a cross-sectional view of the section 2-2 in FIG. 1.

FIG. 3 is a partial cut-away view of the section A of the panel of FIG. 1 illustrating a frame member retained within a sleeve, and a magnet secured to the fabric adjacent the sleeve.

FIG. 4 is a partial cut-away view of the section A of the panel of FIG. 1 illustrating a frame member retained within a sleeve, and a magnet secured as part of the sleeve.

FIG. 5 is a partial cut-away view of the section B of the panel of FIG. 1 illustrating a magnet secured to the fabric.

FIGS. 6A through 6D illustrate how the collapsible structure of FIG. 1 may be twisted and folded for compact storage.

FIG. 7 illustrates another system of collapsible panels and structures according to the present invention.

FIGS. 8A and 8B illustrate how three panels can be connected by two magnetic connectors.

FIGS. 9 and 10 illustrate the use of stabilizing members to support the structures of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims.

As shown in FIGS. 1-6, a structure 20 is provided that comprises four panels 22, 24, 26 and 28 connected to each other to encircle an enclosed space. Each panel 22, 24, 26, 28 can have four sides, such as a left side 30, a bottom side 32, a right side 34 and a top side 36, although each panel 22, 24, 26, 28 can assume any configuration and have any number of sides, Each panel 22, 24, 26 and 28 has a frame retaining sleeve 38 provided along and traversing the four edges of its four sides 30, 32, 34 and 36. A frame member 40 is retained or held within each respective frame retaining sleeve 38 to support each panel 22, 24, 26, 28. Only the frame member 40 is shown in FIGS. 3 and 4; the other frame members are not shown but are the same as frame member 40.

The frame members 40 may be provided as one continuous loop, or may comprise a strip of material connected at both ends to form a continuous loop. The frame members 40 are preferably formed of flexible coilable steel, although other materials such as plastics may also be used. The frame members should be made 30, of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, each frame member 40 is capable of assuming two positions or orientations, an open or expanded position such as shown in FIG. 1, or a folded position in which the frame member is collapsed into a size which is much smaller than its open position (see FIG. 6D).

Fabric or sheet material 42 extends across each respective panel 22, 24, 26, 28, and is held taut by the respective frame member 40 when in its open position. The term fabric is to be given its broadest meaning and should be made from strong, lightweight materials and may include woven fabrics, sheet fabrics or even films. The fabric should be water-resistant and durable to withstand the wear and tear associated with rough treatment. The frame members 40 may be merely retained within the respective frame retaining sleeves 38 without being connected thereto. Alternatively, the frame retaining sleeves 38 may be mechanically fastened, stitched, fused, or glued to the respective frame members 40 respectively, to retain them in position.

FIG. 2 illustrates one possible connection for connecting adjacent edges of two panels 22 and 24. The fabric pieces 42 are stitched at their edges by a stitching 44 to the respective sleeves 38. Each sleeve 38 may be formed by folding a piece of fabric. The stitching 44 also acts as a hinge for the panels 22 and 24 to be folded upon each other, as explained below. The connections for the three other pairs of adjacent edges may be identical. Thus, the connections on the left side 30 and the right side 34 of each panel 22, 24, 26, 28 act as hinge connections for connecting an adjacent panel.

At the top side 36 and the bottom side 32 of each panel 22, 24, 26, 28, where there is no hinge connection to an adjacent panel, the frame retaining sleeve 38 may be formed by merely folding over the corresponding fabric piece and applying a stitching 46 (see FIGS. 3 and 4). The fabric piece 42 for the corresponding panel may then be stitched to the sleeve 38.

While the structure 20 of FIG. 1 is shown and described as having four panels, each having four sides, it will be appreciated that the structure 20 may be made of any number of panels, each having any number of sides, without departing from the spirit and scope of the present invention. For example, each structure may have at least one panel, and each panel may have three or more sides. Thus, the structures of the present invention may take a variety of external shapes. However, each panel, regardless of its shape, is supported by at least one frame member 40.

FIGS. 6A through 6C describe the various steps for folding and collapsing the structure 20 of FIG. 1 for storage. The first step consists of pushing panels 22 and 24 towards panels 28 and 26, respectively, about their hinged connections so that panel 22 collapses upon panel 28 and panel 24 collapses upon panel 26. Then, the two panels 22 and 28 are folded so as to be collapsed upon the two panels 24 and 26 to form a stack of four panels. In the second step, the structure 20 is then twisted and folded to collapse the frame members 40 and panels 22, 24, 26, 28 into a smaller shape. In particular, the opposite border 60 of the stack of panels 22, 24, 26, 28 is folded in (see arrow 62 in FIG. 6A) upon the previous fold to further collapse the frame members 40 with the panels. As shown in FIGS. 6B and 6C, the folding is continued so that the initial size of the structure 20 is reduced until the frame members 40 and panels are collapsed on each other (see FIG. 6D) to provide for a small essentially compact configuration having a plurality of concentric frame members 40 and layers of the panels 22, 24, 26, 28 so that the collapsed structure 20 has a size which is a fraction of the size of the initial structure.

The present invention provides magnetic connectors that allow a number of other items to be removably connected to the structure 20. For example, as shown in FIG. 1, other panels 48 and 50 (which can be identical in construction to the any of the panels 22, 24, 26, 28) can be removably coupled to any panel 22, 24, 26, 28 via magnetic connectors 52. Similarly, another structure 54 (which can be identical in construction to the structure 20 but smaller in size) can also be removably coupled to any panel 22, 24, 26, 28 via magnetic connectors 52.

The magnetic connectors 52 are illustrated in greater detail in FIGS. 2-5. The present invention provides many ways to embody the magnetic connectors 52.

In one embodiment, each magnetic connector 52 can be comprised of a piece of magnet 58 encased inside a fabric pouch 56 (see FIG. 1). This connector 52 can be used in a simple manner, by placing it on an edge of the panel 28 and then aligning an edge of the other panel 50 to the connector 52. Since the frame members 40 in the panels 28 and 50 are made of metal, they will experience a strong attraction to the connector 52 and therefore the two panels 28 and 50 will be coupled at the location of the connector 52. By providing multiple connectors 52, as shown in FIG. 1 along the same edges of the panels 28 and 50, and positioning these connectors 52 between the frame members 40 of two panels (e.g., 28 and 50), a very strong connection can be created between the two panels 28, 50. This type of connector 52 will also allow the user to connect any metallic item to an edge of any of the panels 22, 24, 26, 28, and 50. This is also shown in FIG. 7 with the panels 80 and 50.

In another embodiment, magnetic connectors 521 are comprised of a piece of magnet 58 encased inside a compartment formed by the underlying fabric 42 of a panel and a covering piece of fabric 62. See FIG. 5. These connectors 521 are positioned at fixed locations on the panels, and can be used to connect any metallic item to the fabric 42 of the panel at the location of the connectors 521.

In yet another embodiment, a magnetic connector 522 can be secured to the fabric 42 adjacent the sleeve 38. See FIG. 3. The magnetic connectors 522 are comprised of a piece of magnet 58 encased inside a compartment formed by the underlying fabric 42 of a panel and a covering piece of fabric 62, and positioned adjacent the sleeve 38. These connectors 522 are positioned at fixed locations on the panels, and can be used to connect any metallic item to the fabric 42 of the panel at locations along the edge of the panel.

In yet a further embodiment, the magnetic connectors can comprise a piece of magnet 58 secured inside a sleeve 38, as best shown in FIG. 4. The magnet 58 can be secured to a location on the inner wall of the sleeve 38 by glue, or simply through its automatic attraction/connection force with the metallic frame member 40. These magnetic connectors can be used to connect any metallic item to the frame member 40 of the sleeve 38 that it is retained inside.

The magnetic connectors according to the present invention provide a wide variety of options for removably connecting collapsible panels, collapsible structures and other metallic items, thereby providing the consumer with enhanced play variety and enjoyment. FIGS. 1 and 7 illustrate a few examples of these play options.

Referring to FIG. 1, the panel 50 can be coupled to the top of the structure 20 so that the panel 50 can function as a roof. This can be accomplished by using separate connectors 52 to connect the edges of the panel 50 with the top edges 36 of the panels 22, 24, 26, 28. In addition, the panel 48 can be removably coupled to the fabric 42 of panel 26; specifically, magnetic connectors 521 can be stitched to the fabric 42 and they could directly attract (connect) the metallic frame member 40 of the panel 48. Similarly, the structure 54 can be removably coupled to the panel 24 via two sets of magnetic connectors 52 in accordance with the technique shown in FIGS. 8A and 8B, or through magnetic connectors 521 that are stitched to the fabric 42 of the panel 24.

Referring to FIG. 7, the structure 20 can be embellished by adding a fabric roof 70. The roof 70 (which does not have an encircling frame member 40) can be a piece of fabric with magnetic connectors 521 encased along opposite edges 72, 74 of the roof 70, so that these opposite edges 72, 74 can be coupled to the top edges 36 of the panels 22 and 26. In addition, another fabric roof 70 can be used to create a covered area defined by a single panel (e.g., 50 from FIG. 1) and the panel 24 by coupling the opposite edges 72, 74 to the top edges 36 of the panels 24 and 50. Instead of encased connectors 521, it is also possible to use separate connectors 52, and place them on top of the fabric roofs 70 so that each edge 72, 74 of the fabric roofs is sandwiched between a connector 52 and the underlying frame member 40 on the structure 20. Thus, when FIGS. 1 and 7 are compared, it can be seen that the magnetic connectors 52 or 521 allow the panel 50 to be used for different purposes to vary and enhance the play options for the system of panels 50 and structures 20 shown in FIG. 1.

In addition, triangular panels 80 can be provided as part of the system and used in different ways. For example, as shown in FIG. 7, one triangular panel 80 can be coupled to the fabric 42 of the panel 22 simply by using two magnetic connectors 52 to sandwich the fabric of the triangular panel 80 to the fabric 42 of the panel 22. Here, this illustrates how two magnetic connectors 52 can be effectively used to easily couple two fabric pieces together. FIGS. 8A and 8B illustrate this in greater detail, where FIGS. 8A and 8B show three panels PA, PB and PC (which can be identical in construction to panels 22, 24, 26, 28, 50) connected by two magnetic connectors M (which can be identical to 52) by sandwiching them between the connectors M.

In addition, another magnetic connector 52 can be used to couple the fabric of a triangular panel 80 to a side of the frame member 42 of the panel 50 in a manner where the panel 80 is perpendicular to the panel 50. Here, the magnetic connector 52 is used to connect to the metallic frame member of the panel 50, with the fabric of the panel 80 sandwiched in between. Another triangular panel 80 can be coupled to the opposite side edge of the panel 50. Thus, the panels 80 can be used as base supports for holding the panel 50 vertically upright.

The present invention provides a unique connection system for use with collapsible panels and structures because it relies on the metallic characteristic of the frame members 40 to couple other panels and items. Specifically, the metallic frame members 40 would attract to magnets, so the present invention uses the magnetic forces to create connection points. This provides a much more flexible system of connectors when compared with other known connectors (e.g., VELCRO™ pads, fabric connectors, etc.), and is more convenient and easy to use.

Since the collapsible structures 20 and panels of the present invention are often used to support other panels, structures and items, stability can become compromised. Therefore, stabilizing members can be provided to help maintain the stability of the resulting structure. Referring now to FIG. 9, the structure 20 can be provided with a stabilizing assembly 100 which includes fabric extensions 102, 104 and a supporting bar-and-cord frame 106. Specifically, fabric extensions 102, 104 extend on either side of a panel (e.g., 22), and each extension 102, 104 has a curved or arc shape. Spaced-apart sleeve portions 108 are provided along the top of the extensions 102, 104, and along the top edge 36 of the panel 22, so that the sleeve portions 108 together define a semi-circular shape. The bar-and-cord frame 106 is comprised of a plurality of bar pieces 112 separated by cords 114. The bar pieces 112 have opposing ends that are adapted to be tight-fitted to the ends of adjacent bar pieces 112 so that the bar-and-cord frame 106 defines a semi-circular shape when completely assembled for deployment. The assembled bar-and-cord frame 106 can be inserted through the sleeve portions 108 so that the bar-and-cord frame 106 can function as a stabilizing member to the side of the structure defined by the panel 22.

FIG. 10 illustrates a different type of bar-and-cord frame where two such frames 120 are deployed on the fabric 42 of the panel 22 in a crossing or “₊” shaped configuration, as defined by sleeve portions 124 positioned on the fabric 42 to define the configuration.

FIG. 10 also illustrates another type of stabilizing member, which can take the form of another panel 140. Specifically, magnetic connectors 521 can be sewn onto specific locations of the fabric 42 of the panel 26 and the floor fabric 132, and then the panel 140 can be coupled to the panel 28 and the floor by placing the edges of the panel 140 against these connectors 521 so that the edges of the metallic frame member 40 inside the panel 140 can be coupled to the connectors 521. As a result, the panel 140 can function as a stabilizing member by being positioned in an angled manner to hold the panel 26 upright against the floor.

As yet another example, as shown in FIG. 7, the triangular panels 80 can be used as stabilizing members for a single panel 50.

The principles of the present invention also allow a variety of other items to be removably coupled to a collapsible structure or panel even without the use of the magnetic connectors 52, 521 or 522. Specifically, the metallic nature of the frame members 40 allow for any object having a magnet incorporated therein to be coupled to the frame members 40.

For example, referring to FIG. 9, a base plate 130 defines a planar upper surface that has a plurality of studs 132 provided thereon. Magnet pieces 134 can be housed inside the base plate 130. The base plates 130 can be used to removably couple play objects 136 that are supported on a base 138. The base 138 is adapted to be coupled to the studs 132 on the support base plates 130 in a manner that is similar to a LEGO™ connection. Specifically, most LEGO™ brick pieces have two basic components: studs on top and tubes on the inside. A brick's studs are slightly bigger than the space between the tubes and the walls. When the bricks are pressed together, the studs push the walls out and the tubes in. The material is resilient and wants to hold its original shape, so the walls and tubes press back against the studs, Friction also plays a role, preventing the two bricks from sliding apart. This stud-and-tube coupling system uses an interference fit, which provides a firm, friction-based connection between two parts without the use of an additional fastener, Thus, the bottom of the base 138 would also include the tubes and walls that are normally found at the base of a conventional LEGO™ brick.

Therefore, in FIG. 9, the base plate 130 itself has a magnet 134 that allows it to be removably coupled to the frame member 40 of any of the panels 22, 24, 26, 28.

While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. 

1-13. (canceled)
 14. A collapsible panel comprising a foldable frame member that has a folded and an unfolded orientation, with a fabric material covering portions of the frame member to form the panel when the frame member is in the unfolded orientation, the panel having a bordering sleeve that retains the frame member, and having a magnet piece secured inside the sleeve.
 15. The panel of claim 14, wherein the frame member is a metallic frame member, and the magnet piece is secured to the frame member through the magnetic attraction between the metallic frame member and the magnet piece.
 16. An assembly, comprising: a plurality of panels, the plurality of panels including at least a first panel and a second panel, each panel having a foldable frame member that has a folded and an unfolded orientation, with a fabric material covering portions of each respective frame member to form the panel for each frame member when the frame member is in the unfolded orientation, each panel having a first fabric side and a second fabric side; wherein the first and second panels are positioned side-by-side against each other with the second fabric side of the first panel adjacent the first fabric side of the second panel; a first magnet piece positioned on first fabric side of the first panel; and a second magnet piece positioned on the second fabric side of the second panel at a location that is aligned with the location of the first magnet piece, such that the magnetic connection of the first and second magnet pieces maintains the first and second fabric pieces together. 